Custom Mouthguard

ABSTRACT

An apparatus and a method are provided for a custom mouthguard to protect a user&#39;s teeth from damage due to incident forces. The mouthguard comprises a hard plastic tray portion which is custom fitted to the user&#39;s upper teeth, a soft plastic layer molded over the hard plastic tray, a force distributing layer adhered across a front portion of the soft plastic layer, and an outer compressive portion comprising a portion of the soft plastic layer molded over the force distributing layer. A force incident at the front of the custom mouthguard is partially absorbed by the outer compressive portion and partially transferred to the force distribution layer. The force distribution layer disperses the remaining force throughout the custom mouthguard. Any remaining portion of the force which is transferred to the user&#39;s teeth and nearby bone structures is insufficient to loosen or displace the user&#39;s teeth.

RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. Provisional Application, entitled “Carbon Fiber Mouthguard,” filed on Dec. 18, 2012 having application Ser. No. 61/738,994.

FIELD

The field of the present invention generally relates to mouthguards. More particularly, the field of the invention relates to an apparatus and a method for a custom mouthguard to protect a user's teeth from damage due to incident forces.

BACKGROUND

Conventional mouthguards often are comprised of a soft material so as to prevent a user from injuring or losing teeth during potentially ballistic sports such as hockey, boxing, and martial arts. The softness of the material, however, may not provide sufficient impact resistance for large forces as the material may be unable to absorb and/or disperse the large force throughout the mouthguard. The result typically is damage to one or more teeth due to the concentration of force on a single tooth or on a small cluster of teeth. Thus, conventional mouthguards often are unable to provide sufficient protection to the teeth during sports in which concentrated forces are commonplace such as hockey, boxing, and martial arts.

One solution has been to include additional soft material within the conventional mouthguard. Adding more material, however, makes the mouthguard increasingly bulky, leaving the user unable to comfortably breathe and talk while using the mouthguard. Moreover, in some instances, the bulkiness of the conventional mouthguard may even result in blisters forming in the mouth of the user. Therefore, there is a need for thinner, stronger, and lighter mouthguard which protects a user's teeth from damage due to incident forces experienced during ballistic activities and sports such as hockey, boxing, and martial arts.

SUMMARY

An apparatus and a method are provided for a custom mouthguard to protect a user's teeth from damage due to incident forces. The mouthguard comprises a hard plastic tray portion, a soft plastic layer molded over and adhered to the hard plastic tray, a force distributing layer adhered across a front portion of the soft plastic layer, and an outer compressive portion comprising a portion of the soft plastic layer molded over the force distributing layer. The hard plastic tray portion is aligned with and fitted to the user's upper teeth. The soft plastic layer and the hard plastic tray portion form an inner compressive portion of the custom mouthguard, which is configured to absorb forces. The outer compressive portion is configured to absorb a portion of an incident force and thereby reduces the total force imparted to the force distributing layer. The force distributing layer is configured to direct forces incident at the front of the mouthguard away from the user's front teeth and disperse the forces toward the rear teeth and nearby bone structures. The force distribution layer preferably is comprised of a material capable of flexing while retaining a degree of rigidity suitable for directing forces away from the user's front teeth toward the rear teeth and nearby bone structures. During operation of the custom mouthguard, a total force incident at the front of the custom mouthguard comprises a first portion of the force which is absorbed by the outer compressive portion, a second portion which is transferred to the force distribution layer and then dispersed throughout the custom mouthguard, a third portion which is absorbed by the inner compressive portion, and a forth portion which is transferred to the user's teeth and nearby bone structures such that the forth portion is insufficient to loosen or displace the user's teeth.

In an exemplary embodiment, an apparatus for a custom mouthguard to protect a user's teeth from incident forces comprises a hard plastic tray portion aligned with and fitted to the user's upper teeth, a soft plastic layer molded over and adhered to the hard plastic tray portion to form an inner compressive portion of the custom mouthguard, wherein the inner compressive portion is configured to absorb forces received thereto, a force distributing layer adhered across a front portion of the soft plastic layer, wherein the force distributing layer is configured to direct forces incident at the front of the mouthguard away from the patient's front teeth and disperse the forces toward the rear teeth and nearby bone structures, and an outer compressive portion comprising a portion of the soft plastic layer molded over the force distributing layer, wherein the outer compressive portion is configured to absorb a portion of an incident force and thereby reduces the total force imparted to the force distributing layer.

In another exemplary embodiment, a total force imparted to the custom mouthguard during an impact event comprises a first portion which is absorbed by the outer compressive portion, a second portion which is transferred to the force distribution layer and then dispersed throughout the custom mouthguard, a third portion which is absorbed by the inner compressive portion, and a forth portion which transferred to the user's teeth and nearby bone structures such that the forth portion is insufficient to loosen or displace the user's teeth.

In another exemplary embodiment, the hard plastic tray portion comprises approximately 1 mm thick hard plastic. In another exemplary embodiment, the inner compressive portion of the mouthguard is softer than the hard plastic tray portion. In another exemplary embodiment, the soft plastic layer has a thickness between substantially 3 mm and 4 mm. In another exemplary embodiment, the soft plastic layer is substantially transparent or translucent. In another exemplary embodiment, the soft plastic layer has a color selected by the user. In another exemplary embodiment, the soft plastic layer has a black color. In another exemplary embodiment, the soft plastic layer comprises ethylene vinyl acetate (EVA).

In another exemplary embodiment, the force distribution layer is comprised of a material which is capable of flexing while retaining a degree of rigidity suitable for directing forces away from the user's front teeth toward the rear teeth and nearby bone structures. In another exemplary embodiment, the force distribution layer comprises a bow structure including a middle portion which is positioned within the mouthguard such that a space exists between the middle portion and the user's front teeth, such that the bow structure flexes under the operation of an incident force, thereby absorbing and dispersing the incident force toward the rear teeth and nearby bone structures. In another exemplary embodiment, the bow structure comprises unidirectional carbon fiber.

In another exemplary embodiment, the force distribution layer comprises a carbon fiber layer. In another exemplary embodiment, the carbon fiber layer has a thickness between substantially 0.005 mm and 0.015 mm. In another exemplary embodiment, the carbon fiber layer is adhered to the soft plastic layer by way of an application of heat and an adhesive. In another exemplary embodiment, the carbon fiber layer is adhered to the soft plastic layer by way of an adhesive chemical layer.

In another exemplary embodiment, the custom mouthguard is further customized by imprinting the user's lower teeth onto a bottom portion of the mouthguard. In another exemplary embodiment, the custom mouthguard is characterized by a lower weight than conventional mouthguards. In another exemplary embodiment, the custom mouthguard comprises an adhesion of the force distribution layer to a conventional mouthguard.

In an exemplary embodiment, a method for a custom mouthguard to protect a user's teeth from incident forces comprises obtaining a negative impression of the user's mouth, including the user's upper teeth, modeling the user's upper teeth by pouring suitably mixed green stone poured into the negative impression, allowing the green stone to solidify, and retrieving the model from the negative impression, heating the hard plastic tray portion onto the model such that the hard plastic tray portion becomes aligned with and fitted to the model, heating a soft plastic layer onto the hard plastic tray portion to form an inner compressive portion of the custom mouthguard, wherein the inner compressive portion is configured to absorb forces received thereto, adhering a force distributing layer across a front portion of the soft plastic layer such that the force distributing layer is configured to direct forces incident at the front of the mouthguard away from the patient's front teeth and disperse the forces toward the rear teeth and nearby bone structures, and molding a portion of the soft plastic layer over the force distributing layer to form an outer compressive portion configured to absorb a portion of an incident force and thereby reduces the total force imparted to the force distributing layer.

In another exemplary embodiment, heating the hard plastic tray portion comprises placing the hard plastic tray portion and the model into a Drufomat Scan for a predetermined period of time. In another exemplary embodiment, the predetermined time comprises heating for substantially 1 minute, and then pressing the hard plastic tray portion at substantially 87 PSI for substantially 6 minutes. In another exemplary embodiment, heating the soft plastic layer onto the hard plastic tray portion further comprises placing the soft plastic layer and the hard plastic tray portion into a Drufomat Scan for a predetermine period of time. In another exemplary embodiment, the period of time comprises heating for substantially 50 seconds and pressing for substantially 6 minutes. In another exemplary embodiment, the inner compressive portion of the mouthguard is softer than the hard plastic tray portion.

In another exemplary embodiment, molding further comprises selecting a material for the force distributing layer which is capable of flexing while retaining a degree of rigidity suitable for directing forces away from the user's front teeth toward the rear teeth and nearby bone structures. In another exemplary embodiment, molding further comprises configuring the force distribution layer into a bow structure including a middle portion which is positioned within the mouthguard such that a space exists between the middle portion and the user's front teeth, such that the bow structure flexes under the operation of an incident force, thereby absorbing and dispersing the incident force toward the rear teeth and nearby bone structures. In another exemplary embodiment, the material for the force distributing layer comprises a carbon fiber layer having a thickness of between substantially 0.005 mm and 0.015 mm. In another exemplary embodiment, adhering the force distributing layer further comprises an application of heat. In another exemplary embodiment, molding further comprises placing the hard plastic tray portion, the inner compressive portion, and the force distributing layer into a Drufomat Scan for substantially 3 minutes of heating and substantially 8 minutes of pressing.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings refer to embodiments of the present invention in which:

FIG. 1 depicts an impression of a patient's teeth according to an embodiment;

FIG. 2 depicts a model of a patient's teeth according to an embodiment;

FIG. 3 depicts a hard plastic tray portion and a model of a user's teeth according to an embodiment;

FIG. 3A depicts an embodiment of a negative impression and a hard plastic tray portion according to the present invention;

FIG. 3B depicts an embodiment of a hard plastic tray portion which closely aligns with a user's upper teeth in accordance with the present invention;

FIG. 4 depicts a hard plastic tray portion with a soft plastic layer in accordance with the present invention;

FIG. 5 depicts a force distribution layer according to the present invention;

FIG. 6 depicts a force distribution layer being adhered to a soft plastic layer according to the present invention;

FIG. 6A depicts a force distribution layer comprising a bow structure according to the present invention;

FIG. 7 depicts a custom mouthguard in accordance with the present invention;

FIG. 8 depicts an embodiment of a custom mouthguard utilizing a force distribution layer and an outer compressive portion in accordance with the present invention; and

FIG. 9 depicts an embodiment of a custom mouthguard utilizing a force distribution layer and an outer compressive portion in accordance with the present invention.

While the present invention is subject to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. The invention should be understood to not be limited to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention.

DETAILED DISCUSSION

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one of ordinary skill in the art that the present invention may be practiced without these specific details. The specific details may be varied from and still be contemplated to be within the spirit and scope of the present invention.

In an embodiment, a custom mouthguard is formed by obtaining a custom impression of a user's mouth as shown, for example, in FIG. 1 and a negative impression 102 is taken. In one embodiment, the negative impression 102 is for upper teeth of the user. The negative impression 102 is used to create a model of the user's upper teeth, which may be, for example, a positive impression. In an embodiment, green stone is mixed thoroughly and evenly before pouring it slowly into the negative impression 102 to form an exact model 104 of the user's upper teeth and avoid any air bubbles. The model 104 of the user's upper teeth is trimmed into a desired shape, as shown in FIG. 2, using a stationary grinder.

The model 104 of the user's teeth is placed in a Drufomat Scan, which is a pressure thermoforming machine. A substantially 1 mm thick hard plastic layer is also placed in the Drufomat Scan along with the model 104 of the user's upper teeth. The Drufomat Scan will heat the thick hard plastic layer so that it envelopes the model 104 of the user's teeth to form a hard plastic tray portion 106 of the mouthguard. In an embodiment, the Drufomat Scan heats the hard plastic layer 106 for substantially 1 minute before pressing the hard plastic material at substantially 87 PSI. In an embodiment, the pressing step may take substantially 6 minutes. The hard plastic tray portion 106 may be configured to be closely aligned with and fitted to the model 104 of the user's upper teeth, as shown in FIG. 3. Another embodiment of the negative impression 102 and the hard plastic tray portion 106 are shown in FIG. 3A. In FIG. 3B, an embodiment of the hard plastic tray portion 106 which closely aligns and fits with the user's upper teeth is shown. Once the hard plastic tray portion 106 is formed, the hard plastic tray portion 106 can be trimmed to remove any excess plastic material, as shown in FIGS. 3A-3B.

The hard plastic tray portion 106 is placed in the Drufomat scan along with a soft plastic layer 108 as shown in FIG. 4. The soft plastic layer 108 is then molded over and adhered to the hard plastic tray portion 106 to form an inner compressive portion 110 of the mouthguard. In an embodiment, the inner compressive portion 110 of the mouthguard is softer than the hard plastic tray portion 106. The inner compressive portion 110 is then trimmed to remove any excess material. In an embodiment, the soft plastic layer 108 is substantially 3 mm-4 mm thick. In another embodiment, the soft plastic layer 108 may have a black color, but may also be any desired color. The soft plastic layer 108 may be formed, for example, from ethylene vinyl acetate (EVA). In the Drufomat scan, the soft plastic layer 108 may be heated for substantially 50 seconds, and pressed for substantially 6 minutes. The inner compressive portion 110 preferably is configured to absorb forces incident on the inner compressive portion 110. It will be appreciated by those skilled in the art that the forces transmitted to the hard plastic tray portion 106 will be reduced due to force absorbing properties of the soft plastic layer comprising the inner compressive portion 110.

A force distribution layer 112, as shown in FIG. 5, is placed across a front portion of the soft plastic layer 108. In the embodiment shown, the force distribution layer 112 comprises a carbon fiber layer which is adhered to the soft plastic layer 108 to form a carbon fiber portion of the mouthguard as shown in FIG. 6. The carbon fiber layer 112 may have, for example, a thickness between substantially 0.005 mm and 0.015 mm. The carbon fiber layer 112 may be adhered to the soft plastic layer 108 through the application of heat and/or an adhesive chemical layer.

In one embodiment, the carbon fiber layer 112 may be further customized. In this embodiment, a negative impression 102 of the mouthguard including the hard plastic tray portion 106 and the inner compressive portion 110 can be formed. The negative impression 102 of the hard plastic tray portion 106 and the inner compressive portion 110 may be used to form a positive impression of the hard plastic tray portion 106 and the inner compressive portion 110. The carbon fiber layer 112 may then be temporarily placed over the positive impression of the hard plastic tray portion 106 and the inner compressive portion 110 such that the carbon fiber layer can be trimmed to the desired shape and size.

It will be appreciated that the carbon fiber portion is configured to spread out or disperse forces received by the carbon fiber portion, even when the forces are concentrated in a small area, such as the front of the mouthguard. It will be recognized by those skilled in the art that the force distribution layer 112 need not be limited to a carbon fiber layer, but rather the force distribution layer 112 may comprise any material suitable for directing forces incident at the front of the mouthguard away from the user's front teeth and dispersing the forces toward the rear teeth and nearby bone structures. In another embodiment, the force distribution layer 112 comprises a bow structure, as shown in FIG. 6A, including a middle portion 114 which is positioned within the mouthguard such that a space 116 exists between the middle portion 114 and the user's front teeth. In this embodiment, the bow structure flexes under the operation of an incident force, thereby absorbing and dispersing the incident force toward the rear teeth and nearby bone structures. Experimentation has shown that a bow structure comprising unidirectional carbon fiber, as shown in FIG. 6A, reduces the force transferred to the front teeth by substantially 70% relative to conventional mouthguards. Moreover, the bow structure shown in FIG. 6A facilitates making the custom mouthguard advantageously thinner and lighter than conventional mouthguards. It will be appreciated by those skilled in the art that thinner, lighter mouthguards are preferable due to simplifying breathing and talking while the mouthguard is being used.

Referring to FIGS. 6-7, the mouthguard including the hard plastic tray portion 106, the inner compressive portion 110, and the force distribution layer 112 may be placed in the Drufomat scan machine along with another soft plastic layer so as to form an outer compressive portion 118 over the inner compressive portion 110 and the force distribution layer 112. While in the Drufomat scan, the soft plastic layer may be heated for substantially 3 minutes, and then pressed for substantially 8 minutes. The outer compressive portion 118 may also be trimmed to optimize comfort. In an embodiment, the soft plastic layer may comprise EVA and have a thickness between substantially 3 mm and 4 mm. In an embodiment, shown in FIG. 7, the outer compressive portion may be substantially transparent or translucent. FIG. 8 shows a custom mouthguard utilizing the above-discussed bow structure for the force distribution layer 112 and an outer compressive portion 118 comprising black soft plastic layer. Another embodiment of the custom mouthguard is shown in FIG. 9, comprising the bow structure for the force distribution layer 112. The outer compressive layer of the mouthguard shown in FIG. 9 is transparent, and thus reveals the interior bow structure used for the force distribution layer 112. It will be recognized that the outer compressive portion 118 serves to absorb forces incident on the mouthguard, and thereby reduces the level of force transferred to the force distribution layer 112.

It will be appreciated by those skilled in the art that, in another embodiment, the custom mouthguard may be further customized by heating the mouthguard such that the user can bite onto the mouthguard to imprint the user's lower teeth onto a bottom (not shown) of the custom mouthguard. It will be further appreciated that imprinting the user's lower teeth provides additional customization to the mouthguard so as to aid in securing the mouthguard within the user's teeth during use, as well as increasing the level of comfort experienced during use.

During use of the custom mouthguard, when an incident force is directed onto the mouthguard, the outer compressive portion 118 absorbs some of the force while the remaining force is translated to the force distribution layer 112 and then dispersed over the rest of the mouthguard. The inner compressive portion 110 absorbs a portion of the dispersed force, leaving any remain portion of the force to be translated to the user's teeth and nearby bone structures. it will be appreciated by those of ordinary skill in the art that since the force is widely dispersed, the user's teeth receive a force which is insufficient to loosen or displace the teeth. Thus, the patient will have a reduced likelihood of having a tooth knocked out.

It should be understood that the present invention is not limited solely to the embodiments described herein, but rather other embodiments of the custom mouthguard need not include all of the components disclosed above and may omit, for example, one or more of the hard plastic tray portion 106, the inner compressive portion 110, and/or the outer compressive portion 118. For instance, in another embodiment, the custom mouthguard may be formed simply by adhering the force distribution layer 112 directly onto a conventional mouthguard. Other embodiments and variations will be apparent to those skilled in the art without deviating from the spirit and scope of the present invention.

The previous description of the disclosed examples is provided to enable any person of ordinary skill in the art to make or use the disclosed methods and apparatus. Various modifications to these examples will be readily apparent to those skilled in the art, and the principles defined herein may be applied to other examples without departing from the spirit or scope of the disclosed method and apparatus. The described embodiments are to be considered in all respects only as illustrative and not restrictive and the scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. 

1. An apparatus for a custom mouthguard to protect a user's teeth from damage due to incident forces, the apparatus comprising: a hard plastic tray portion aligned with and fitted to the user's upper teeth; a soft plastic layer molded over and adhered to the hard plastic tray portion to form an inner compressive portion of the custom mouthguard, wherein the inner compressive portion is configured to absorb forces received thereto; a force distributing layer adhered across a front portion of the soft plastic layer, wherein the force distributing layer is configured to direct forces incident at the front of the mouthguard away from the patient's front teeth and disperse the forces toward the rear teeth and nearby bone structures; and an outer compressive portion comprising a portion of the soft plastic layer molded over the force distributing layer, wherein the outer compressive portion is configured to absorb a portion of an incident force and thereby reduces the total force imparted to the force distributing layer.
 2. The apparatus of claim 1, wherein a total force imparted to the custom mouthguard during an impact event comprises a first portion which is absorbed by the outer compressive portion, a second portion which is transferred to the force distribution layer and then dispersed throughout the custom mouthguard, a third portion which is absorbed by the inner compressive portion, and a forth portion which transferred to the user's teeth and nearby bone structures such that the forth portion is insufficient to loosen or displace the user's teeth.
 3. The apparatus of claim 1, wherein the hard plastic tray portion comprises approximately 1 mm thick hard plastic.
 4. The apparatus of claim 1, wherein the inner compressive portion of the mouthguard is softer than the hard plastic tray portion.
 5. The apparatus of claim 1, wherein the soft plastic layer has a thickness between substantially 3 mm and 4 mm.
 6. The apparatus of claim 1, wherein the soft plastic layer is substantially transparent or translucent.
 7. The apparatus of claim 1, wherein the soft plastic layer has a color selected by the user.
 8. The apparatus of claim 7, wherein the soft plastic layer has a black color.
 9. The apparatus of claim 8, wherein the soft plastic layer comprises ethylene vinyl acetate (EVA).
 10. The apparatus of claim 1, wherein the force distribution layer is comprised of a material which is capable of flexing while retaining a degree of rigidity suitable for directing forces away from the user's front teeth toward the rear teeth and nearby bone structures.
 11. The apparatus of claim 10, wherein the force distribution layer comprises a bow structure including a middle portion which is positioned within the mouthguard such that a space exists between the middle portion and the user's front teeth, such that the bow structure flexes under the operation of an incident force, thereby absorbing and dispersing the incident force toward the rear teeth and nearby bone structures.
 12. The apparatus of claim 11, wherein the bow structure comprises unidirectional carbon fiber.
 13. The apparatus of claim 10, wherein the force distribution layer comprises a carbon fiber layer.
 14. The apparatus of claim 13, wherein the carbon fiber layer has a thickness between substantially 0.005 mm and 0.015 mm.
 15. The apparatus of claim 13, wherein the carbon fiber layer is adhered to the soft plastic layer by way of an application of heat and an adhesive.
 16. The apparatus of claim 13, wherein the carbon fiber layer is adhered to the soft plastic layer by way of an adhesive chemical layer.
 17. The apparatus of claim 1, wherein the custom mouthguard is further customized by imprinting the user's lower teeth onto a bottom portion of the mouthguard.
 18. The apparatus of claim 1, wherein the custom mouthguard is characterized by a lower weight than conventional mouthguards.
 19. The apparatus of claim 1, wherein the custom mouthguard comprises an adhesion of the force distribution layer to a conventional mouthguard.
 20. A method for a custom mouthguard to protect a user's teeth from damage due to incident forces, the method comprising: obtaining a negative impression of the user's mouth, including the user's upper teeth; modeling the user's upper teeth by pouring suitably mixed green stone poured into the negative impression, allowing the green stone to solidify, and retrieving the model from the negative impression; heating the hard plastic tray portion onto the model such that the hard plastic tray portion becomes aligned with and fitted to the model; heating a soft plastic layer onto the hard plastic tray portion to form an inner compressive portion of the custom mouthguard, wherein the inner compressive portion is configured to absorb forces received thereto; adhering a force distributing layer across a front portion of the soft plastic layer such that the force distributing layer is configured to direct forces incident at the front of the mouthguard away from the patient's front teeth and disperse the forces toward the rear teeth and nearby bone structures; and molding a portion of the soft plastic layer over the force distributing layer to form an outer compressive portion configured to absorb a portion of an incident force and thereby reduces the total force imparted to the force distributing layer.
 21. The method of claim 20, wherein heating the hard plastic tray portion comprises placing the hard plastic tray portion and the model into a Drufomat Scan for a predetermined period of time.
 22. The method of claim 21 wherein the predetermined time comprises heating for substantially 1 minute, and then pressing the hard plastic tray portion at substantially 87 PSI for substantially 6 minutes.
 23. The method of claim 20, wherein heating the soft plastic layer onto the hard plastic tray portion further comprises placing the soft plastic layer and the hard plastic tray portion into a Drufomat Scan for a predetermine period of time.
 24. The method of claim 23 wherein the period of time comprises heating for substantially 50 seconds and pressing for substantially 6 minutes.
 25. The method of claim 20, wherein the inner compressive portion of the mouthguard is softer than the hard plastic tray portion.
 26. The method of claim 20, wherein said molding further comprises selecting a material for the force distributing layer which is capable of flexing while retaining a degree of rigidity suitable for directing forces away from the user's front teeth toward the rear teeth and nearby bone structures.
 27. The method of claim 26, wherein said molding further comprises configuring the force distribution layer into a bow structure including a middle portion which is positioned within the mouthguard such that a space exists between the middle portion and the user's front teeth, such that the bow structure flexes under the operation of an incident force, thereby absorbing and dispersing the incident force toward the rear teeth and nearby bone structures.
 28. The method of claim 26, wherein the material comprises a carbon fiber layer having a thickness of between substantially 0.005 mm and 0.015 mm.
 29. The method of claim 20, wherein said adhering the force distributing layer further comprises an application of heat
 30. The method of claim 20, wherein said molding further comprises placing the hard plastic tray portion, the inner compressive portion, and the force distributing layer into a Drufomat Scan for substantially 3 minutes of heating and substantially 8 minutes of pressing. 